Transport pallet for creating modular configurable structures

ABSTRACT

A pallet configured to be coupled to another pallet to form a modular structure. The pallet includes a top surface and a bottom surface including a longitudinal center axis. First and second cross-bar elements are coupled to and extend outward from the bottom surface. The first cross-bar element is positioned parallel to and at a first distance from the center axis, and the second cross-bar element positioned parallel to and at a second distance from the center axis different than the first distance.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/758,612 filed on Jan. 30, 2013.

BACKGROUND OF THE INVENTION

Field shelters are often constructed as container-based systems, trailer-based systems, or tent-based systems. These systems must be delivered to the field site, for example through pallet-based shipments. While container-based systems and trailer-based systems are advantageous in terms of protection and load-bearing capabilities, they are not flexible structures and can greatly increase the weight and size of shipments to the field site. On the other hand, tent-based systems are light-weight and require little room to ship, but provide very little protection. Furthermore, such systems are not flexible with respect to size, shape, or function and, as a result, cannot be readily used in other capacities at a field site, such as for walls, towers, barriers, bridges, etc. Therefore, what is needed is a structural system for field shelters that provides protection and load-bearing capabilities, requires minimal space when delivering to a field site, and can be readily configured to form other structures necessary at the field site.

SUMMARY

The disclosure relates in general to methods and pallet systems for creating strong and reconfigurable modular structures for field applications, for example after such pallets are used to deliver materiel to a field site.

In one implementation, the present disclosure is directed to a pallet configured to be coupled to another pallet to form a modular structure. The pallet includes a top surface and a parallel, adjacent bottom surface with a longitudinal center axis. The pallet also includes a first cross-bar element coupled to and extending outward from the bottom surface. The first cross-bar element is positioned parallel to and at a first distance from the center axis and includes a pinhole configured to receive a bolt. The pallet further includes a second cross-bar element coupled to and extending outward from the bottom surface. The second cross-bar element is positioned parallel to and at a second distance from the center axis, different than the first distance, and includes a pinhole configured to receive a bolt.

In another implementation, the present disclosure is directed to a pallet system including a first pallet and a second pallet. The first pallet includes a bottom surface with a first cross-bar element coupled to and extending outward from the bottom surface and a second cross-bar element coupled to and extending outward from the bottom surface. The second pallet includes a bottom surface with a first cross-bar element coupled to and extending outward from the bottom surface and a second cross-bar element coupled to and extending outward from the bottom surface. When the first pallet and the second pallet are stacked, the first cross-bar element of the first pallet is aligned adjacent to the second cross-bar element of the second pallet, and the second cross-bar element of the first pallet is aligned adjacent to the first cross-bar element of the second pallet.

In yet another implementation, the present disclosure is directed to a method for creating a modular pallet structure. The method includes providing a first pallet including a first side edge, a bottom surface with a longitudinal center axis, a first cross-bar element coupled to and extending outward from the bottom surface, and a second cross-bar element coupled to and extending outward from the bottom surface. The first cross-bar element is positioned parallel to and at a first distance from the center axis, while the second cross-bar element is positioned parallel to and at a second distance from the center axis, different than the first distance. The method also includes providing a second pallet including a second side edge, a bottom surface with a longitudinal center axis, a first cross-bar element coupled to and extending outward from the bottom surface, and a second cross-bar element coupled to and extending outward from the bottom surface. The first cross-bar element is positioned parallel to and at the first distance from the center axis, while the second cross-bar is element positioned parallel to and at the second distance from the center axis. The method further includes aligning the first side edge with the second side edge, and coupling together the first cross-bar element of the first pallet with the first cross-bar element of the second pallet with a connector and a bolt.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of a pallet according to one aspect of the present invention.

FIG. 2 is a side view of a pallet pair comprising two pallets coupled together in accordance with an aspect of the present invention.

FIG. 3 is a perspective view of a pallet pair.

FIG. 4 is a front view of a modular pallet structure according to one aspect of the invention.

FIG. 5 is a side view of another modular pallet structure according to one aspect of the invention.

FIG. 6 is a partial side view of a connection joint connecting two pallets together.

FIG. 7 is a partial side view of another connection joint connecting two pallets together.

FIG. 8 is a partial side view of yet another connection joint connecting two pallets together.

FIG. 9 is a perspective view of a modular structure in accordance with another aspect of the invention.

FIG. 10 is a perspective view of a structural insulated panel for use with the modular structure of FIG. 9.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to pallet systems and methods for modifying standard pallets to create strong and reconfigurable modular structures for field applications, for example after such pallets are used to deliver materiel to a field site. This modified pallet system can be used to create shelters, barriers, and bridges without adding size or weight to the materiel delivered to the site.

FIG. 1 illustrates a pallet 10 according to one aspect of the invention. The pallet 10 can be a modified standard pallet, such as a modified 463L pallet, that serves as a modular structural component, as further described below. The pallet 10 may be constructed of a single sheet of wood, a sheet of wood sandwiched or covered on either side by aluminum, multiple slats of wood side-by-side (e.g., separated by gaps), multiple layers of material, or a structural insulated panel, as further described below. The pallet 10 can include a bottom surface, or underside, 14 and a parallel, adjacent top surface, or loading side, 16. The bottom surface 14 and the top surface 16 may be directly adjacent to each other (e.g., when the pallet 10 is constructed of a single sheet of wood or other material), or may be indirectly adjacent to each other (e.g., when the pallet 10 is constructed of multiple materials sandwiched or layered together). Generally, the pallet 10 can include at least two cross-bar elements 12 coupled to and extending outward from the bottom surface 14. The two cross-bar elements 12, such as angle or beam spars, can be coupled to the pallet 10 through welding, riveting, gluing, bolting, and/or other suitable methods and can be positioned in an asymmetrical or off-center manner along the pallet 10.

In one specific example, pairs of aircraft aluminum angle or beam spars 12 of roughly 6-inch depth can be welded to the skin of the bottom surface 14. The spars 12 can be “L-shaped” to provide a first section 11 with a coupling surface 13 for welding to the underside 14 of the pallet, as shown in FIG. 1, and a perpendicular second section 15 extending outward from the bottom surface 14 (e.g., about 6 inches). The spars 12 can be positioned parallel to a longitudinal center axis 18 of the pallet 10 and slightly offset from the axis 18 at different distances D1, D2. Each spar 12 can include pinholes 20 (e.g., along the second section 15) to accommodate connection to adjacent spars 12 of other pallets 10 via bolts 22, as shown in FIG. 2 and described below. Generally, D1 and D2 can differ by at least a width W of the second section 15 and at most a length L of the bolt 22 to enable efficient stacking and coupling of pallets 10, as described below. For example, the spars 12 can be spaced at about one-quarter and three-quarters of the width of the pallet 10, respectively, offset by the width W of the second section 15. In addition, in some applications, larger or smaller spars 12, or more than two spars 12 per pallet 10, can be implemented.

As shown in FIG. 1, the loading side 16 of the pallet 10 can remain unmodified to provide a flat surface for loading materials in a conventional manner, for example during material transport. As a result, the original functionality of the pallet 10 for logistical purposes remains unimpaired. In addition to the unaltered top surface 16, the pallet 10 can still interface with lifting and rolling systems and can allow unfettered access to attachment points, such as rings, grommets, tie-downs, etc., similar to conventional pallets. To accommodate such functionality, pallets 10 can be transported in pairs, as shown in FIG. 2. More specifically, paired pallets 10 can be stacked underside-to-underside in a complimentary or opposing manner so that the off-set spars 12 are set adjacent to one another rather than on top of one another. In other words, the off-set spars 12 (that is, the asymmetrical configuration of each set of spars 12) allow the paired pallets 10 to nest together without interfering with each other. This creates a “sandwich” of a pair of two opposing pallets 10, where the first spar 12 of the first pallet 10 aligns adjacent to the second spar 12 of the second pallet 10, and the second spar 12 of the first pallet 10 aligns adjacent to the first spar 12 of the second pallet 10. The spars 12 can then be connected via pins or bolts 22 through adjacent pinholes 20 to provide a paired pallet system 24 with flat loading surfaces 16 identical to unmodified pallets, though, in some applications, with an increased depth in comparison to unmodified pallets. As shown in FIG. 3, materiel 26 can then be loaded and netted on the loading surface 16 of an upper pallet 10, as it would be in a standard unmodified pallet, and delivered to a field site.

After unloading one or more pallet pairs 24 at a field site, the pallet pairs 24 can be broken down into two separate pallets 10. These separate pallets 10 can then be reused as modular structural components for creating a pallet system structure 28, such as that shown in FIGS. 4 and 5. To create such pallet system structures 28, one or more pallets 10 can be aligned edge-to-edge and coupled together at fixed or variable angles using, for example, connecting joints 30 (as shown in FIGS. 4 and 6-8). For example, three pallets 10 can be coupled together to create a three-sided structure 28 built over a tent 27 and capable of supporting a water tank 29 and a solar panel array 31, as shown in FIG. 4. In another example, one or more pallets 10 are used as a structure 28 to provide a make-shift bridge capable of supporting transport vehicles 33, as shown in FIG. 5. In yet another example, one or more pallet 10 can be used to provide a fence around a specific area.

The connecting joints 30 can take any size or shape necessary to connect adjacent pallets. For example, in some applications, the connecting joints 30 may be spars 35 of similar thickness, strength, and/or material of the connecting spars 12 on the pallets 10, as shown in FIGS. 4 and 6. The connecting joints 30 can include pinholes 32 at either end configured to align with pinholes 20 of adjacent pallets 10. The connecting joints 30 can be connected to adjacent pallets 10 (i.e., adjacent spars 12) via bolts or pins 22 through aligned pinholes 20, 32, thus coupling the adjacent pallets 10 together and creating a pallet edge 34. In some applications, the pinholes 20, 32 of both the pallet spars 12 and the connecting joints 30 can be configured to allow a one or more pre-specified pallet edge angles when coupling pallets 10 together. Such angles can include, but are not limited to, about 180 degrees, about 150 degrees, about 135 degrees, about 120 degrees, about 90 degrees, about 60 degrees, and/or about 45 degrees.

The connecting joints 30 can be provided in pairs, as parallel connected spars 12 can create a rigid joint. In addition, a plurality of connecting joint pairs 30 can be provided at fixed lengths to accommodate connections through different pinholes 20 on the spars 12 to create different edge angles. In some applications, pinholes 20 can be labeled accordingly so that the connecting joints 30 may be quickly and easily attached to create a desired edge angle. In some applications, pre-sized triangular gusset plates 36, as shown in FIG. 4, can serve as connecting joints 30. Furthermore, in other applications, outer edge connectors 38, as shown in FIG. 5, can be provided as connecting joints 30. For example, the outer edge connectors 38 can be provided as hinges, spacers, rigid joints, or other similar or suitable connectors. These outer edge connectors 38 can be treated to provide a weather-resistant joint and/or a water-tight seal between connected pallets 10. Also, the connecting joints 30 and any other tools can be packaged and stored in a space 40 between pallet pairs 24 for transportation to the field site, as shown in FIG. 3.

As discussed above, the pallets 10 can be coupled together in various configurations to provide a rapid and easily assembled pallet system structure 28. Such pallet system structures 28 can be configured to shield from weather, to structurally span a space, to structurally enclose a space, etc. Furthermore, through the use of additional protective material, such as sandbags or rock barriers 42 around and on top of the structure 28, as shown in FIG. 4, structures 28 can provide force protection. Specific pallet structure examples 28 include, but are not limited to, three-sided and four-sided tent applications placed in rows for shelter, as shown in FIG. 4, edge-to-edge applications for floors or bridges, as shown in FIG. 5, two-sided triangle applications for barriers, or edge-to-edge applications for fencing. As the structures 28 are built from modular components 10, different configurations can be assembled to easily accommodate one or more occupants and multiple structures 28 can be joined together when desired. These structures 28 can also be load bearing and deployable on uneven ground. In some cases, the strength of the structures 28 (that is, the load bearing capability) can be dependent on a specific application and the configuration of pallets 10. For example, the structures 28 can be at least strong enough to walk on or store items on (such as in tent applications) or strong enough to drive vehicles over (such as in bridge applications).

In addition, structures 28 can be treated and/or augmented on either side 14, 16 with paint coatings, radiant material, or customized ceramic, metallic, or polymer material or coatings for purposes of camouflage, visual marking, thermal enhancement, blast or ballistic protection, or structural enhancement, as desired for a specific application. For example, some modifications or treatments can be implemented after the structures 28 are configured. In another example, each single pallet 10 can be developed with enhanced structural, thermal, blast or ballistic, weight, or material properties. For example, in some applications, pallets 10 may be developed with insulation or may be used in conjunction with structural insulated panels (“SIPs”), as further described below with respect to FIG. 9.

FIG. 9 illustrates another example modular structure 28, according to one aspect of the present invention, assembled for use in a field site. The structure 28 of FIG. 9 can include three modular components, such as the pallets 10 described above and/or structural insulated panels (“SIPs”) 44, coupled together to create a three-sided tent configuration. For example, SIPs 44 can be interchangeable with the pallets 10 in configured pallet structures 28 and both components 10, 44 can be coupled together via connection joints 30, such as outer edge connectors 38, as shown in FIG. 10. Both the SIPs 44 and the pallets 10 can be air-drop ready and, in some cases, the SIPs 44 can be form-packed on the pallets 10 themselves during transport.

The SIPs 44 can be insulated (i.e., between their top and bottom surfaces) and weatherproofed, and can also include windows 46 extending through the top and bottom surfaces, such as passive solar design windows that can be shuttered with shutters 48 in hot weather or at night, as desired. In some applications, the SIPs 44 can comprise corrugated metal 45 (e.g., on the top surface) and/or fiberglass/Kevlar internal armor (e.g., between the top surface and the bottom surface). In addition, the SIPs 44 can include rigid joints that can serve as gutters to catch rain and snow. Additional materials, for example included in the packaging between pallet pairs 24, can also be used to provide and/or connect gutters between pallets 10 and SIPs 44. It is also contemplated that, in some applications the features described above with respect to SIPs 44 may be integrated into pallets 10.

The structure 28 of FIG. 9 can fit one or more occupants, and can be configured with power and/or water amenities. For example, the structure 28 can be set up with a generator 50, a photovoltaic (“PV”) array 52 supported on one modular component 44 with connected PV batteries 54, a controller 56, a light 58, a water pump 60, a grey water tank 62, an untreated well 64 (or surface water supply), a drink water system 66, a shower 68, and a composting toilet 70. The controller 56 can connect to the PV batteries 54 and the generator 50 and can optimize use between the two components 54, 50 to power other components, such as the light 58, the water pump 60, the drink water system 66, the untreated well 64, and/or additional components, such as a fan and/or a radio (not shown). In addition, the grey water tank 62 can be in fluid communication with the gutters of the structure 28 to capture rain and snow for reuse.

An advantage of the system and methods of the present invention is that it can create a load-bearing and highly flexible structure for many field applications that is expedient to utilize and that makes use of pallet materiel that is already being delivered to field sites and which would otherwise be wasted and difficult to discard. The use of pallets in this system replaces the need for logistical operations to deliver additional structural systems. This results in less delivery size and weight as well as better capabilities for field outpost systems. For example, the methods of the present invention produce a system that is lighter and more flexible than conventionally used containers or trailers, and which, unlike tents, has strong load-bearing, and protective capabilities. The structure can also be used in conjunction with or to replace components of other systems.

The materials and methods described above are not intended to be limited to the embodiments and examples described herein. 

1. A pallet configured to be coupled to another pallet to form a modular structure, the pallet comprising: a top surface; a bottom surface parallel and adjacent to the top surface, the bottom surface including a longitudinal center axis; a first cross-bar element coupled to and extending outward from the bottom surface, the first cross-bar element positioned parallel to and at a first distance from the center axis, the first cross-bar element including a pinhole configured to receive a bolt; and a second cross-bar element coupled to and extending outward from the bottom surface, the second cross-bar element positioned parallel to and at a second distance from the center axis, different than the first distance, the second cross-bar element including a pinhole configured to receive a bolt.
 2. The pallet of claim 1, wherein the first cross-bar element and the second cross-bar element are aluminum spars.
 3. The pallet of claim 1, wherein the first cross-bar element and the second cross-bar element are each L-shaped, including a first section and a second section perpendicular to the first section.
 4. The pallet of claim 3, wherein the first section includes a welding surface welded to the bottom surface.
 5. The pallet of claim 3, wherein the second section is about 6 inches long.
 6. The pallet of claim 3, wherein the first distance and the second distance differ by at least a width of the second section.
 7. The pallet of claim 1, wherein the top surface is substantially flat.
 8. The pallet of claim 1, wherein the top surface includes a corrugated metal covering.
 9. The pallet of claim 1, wherein the top surface includes multiple pieces coupled together side-by-side with gaps between the multiple pieces.
 10. The pallet of claim 1 and further comprising insulation between the top surface and the bottom surface.
 11. The pallet of claim 10, wherein the insulation includes at least one of fiberglass and Kevlar.
 12. The pallet of claim 1, wherein the top surface and the bottom surface include a window hole extending there through.
 13. A pallet system comprising: a first pallet including a bottom surface with a first cross-bar element coupled to and extending outward from the bottom surface and a second cross-bar element coupled to and extending outward from the bottom surface; and a second pallet including a bottom surface with a first cross-bar element coupled to and extending outward from the bottom surface and a second cross-bar element coupled to and extending outward from the bottom surface, when the first pallet and the second pallet are stacked, the first cross-bar element of the first pallet is aligned adjacent to the second cross-bar element of the second pallet, and the second cross-bar element of the first pallet is aligned adjacent to the first cross-bar element of the second pallet.
 14. The pallet structure of claim 13, wherein each of the first cross-bar elements and the second cross-bar elements include pinholes configured to receive bolts when the first cross-bar elements are aligned with the second cross-bar elements to couple together the first pallet and the second pallet.
 15. The pallet structure of claim 13 and further comprising a connector configured to couple together the first cross-bar elements when a first edge of the first pallet is aligned adjacent to a second edge of the second pallet.
 16. The pallet structure of claim 15, wherein each of the first cross-bar elements includes a pinhole configured to receive bolts and the connector includes pinholes configured to receive bolts, wherein the connector is configured to couple together the first cross-bar elements through alignment of the pinholes of the connector with the pinhole of each of the first cross-bar elements and insertion of the bolts through the aligned pinholes.
 17. The pallet structure of claim 15, wherein the connector is configured to couple together the first cross-bar elements to create an angle between the first edge and the second edge of one of about 180 degrees, about 150 degrees, about 125 degrees, about 120 degrees, about 90 degrees, about 60 degrees, and about 45 degrees.
 18. The pallet structure of claim 15, wherein the connector is a gusset plate.
 19. The pallet structure of claim 13 and further comprising a connector configured to couple together a top surface of the first pallet with a top surface of the second pallet when a first edge of the first pallet is aligned adjacent to a second edge of the second pallet, wherein the connector is a hinge structure.
 20. A method for creating a modular pallet structure, the method comprising the steps of: providing a first pallet including a first side edge, a bottom surface with a longitudinal center axis, a first cross-bar element coupled to and extending outward from the bottom surface, the first cross-bar element positioned parallel to and at a first distance from the center axis, and a second cross-bar element coupled to and extending outward from the bottom surface, the second cross-bar element positioned parallel to and at a second distance from the center axis, different than the first distance; providing a second pallet including a second side edge, a bottom surface with a longitudinal center axis, a first cross-bar element coupled to and extending outward from the bottom surface, the first cross-bar element positioned parallel to and at the first distance from the center axis, and a second cross-bar element coupled to and extending outward from the bottom surface, the second cross-bar element positioned parallel to and at the second distance from the center axis; aligning the first side edge with the second side edge; and coupling together the first cross-bar element of the first pallet with the first cross-bar element of the second pallet with a connector and a bolt. 